Tray assembly for germination floor

ABSTRACT

A tray assembly for a germination floor assembly having a perforation tray sheet affixed to a rectangular frame assembly. The frame assembly includes a pair of parallel side members interconnected by a pair of end cross frame members. A plurality of longitudinal ribs extend parallel to the side members between the cross frame members. Reinforcing cross bars further extend between the side members and the longitudinal ribs. The cross frame members and reinforcing cross bars have a unique configuration to provide unimpeded flow of liquid wash through the tray assembly during cleaning. A tray assembly is attached to an adjacent tray by a bolt assembly. The tray assembly may be attached to supporting I-beams by hold down clamps. In one embodiment risers are employed for enhanced free flow of liquid wash during cleaning.

This is a division of application Ser. No. 248,312, filed Sept. 19,1988.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to germination compartments for germinating grainand, more particularly, to germination tray assemblies forming the floorin a germination compartment.

2. Description of the Prior Art

Germination compartments have long been used to germinate grain in aprocess called malting. The grain is placed on a plurality of perforatedtrays forming a floor assembly and are subjected to germination bycontrolled temperature and humidity in the compartment.

A major problem in the malting process is the control of contaminationand unwanted residue, which must be removed after each three or four daygermination cycle, using clear water and then treating the germinationarea with a clorine water solution to reduce unwanted bacterial growth.The fragrance of germinating malt in a clean, well maintainedgermination compartment is pleasant, whereas the stench in a compartmentpoorly cleaned or maintained is pungent and very offensive.

The prior floor structure, devised about 1900 to 1910, and stillcommonly used today, has many undesirable features making it extremelydifficult to clean properly and must be treated with a heavy solution ofclorine and water. In the prior art the frame structure for eachperforated tray is constructed of a steel channel, outside peripheralmembers, and steel angle ribs extending across the width of the frame. Aperforated sheet is attached to the top of the frame in an offsetposition so the overlap on two sides extends over the adjoining frame ona recessed surface provided. In prior times, the cleaning was lessintensive and less expensive, unlike present day standards.

The old trays are freely placed on supporting I-beams where bacterialgrowth between the tray frames under the overlapping sheet and thehidden inaccessible pockets of the channels are major problem areas. Thewash crew is required to perform under very adverse conditions in asubfloor chamber which has a 100% humidity and due to the offfall fromthe barley, gets very slippery after the three or four day germinatingcycle. The angle ribs are difficult to clean on the underside surface.The configuration of the past tray frame provides nooks, cranies,pockets or cavities that serve as reservoirs for the accumulation ofcontamination and slime, which is detrimental to the growth andproduction of high quality malt during the germination cycle.

Another concern of maltsters with reference to germination trays iswhether the floor assembly provides a sufficient open area for thepassage of air and moisture during the germination process. In priorart, an individual tray assembly having a representative length of 120inches and width of 44.5 inches, has approximately 37 square feet ofarea. Since the surface area of the frame components is 8.6875 squarefeet, 24% of the frame area is closed to free flow of air and humiditycirculation.

The old trays also have unprotected tray sheets on the extended surfacesand are frequently damaged by the mechanical plow board used to removethe barley from the compartment floor after the germinating cycle. Withthe new unloading equipment now being devised to operate automaticallyunloading the germinated barley from the compartment floor, damage totrays is a serious consideration.

The prior designs also fail to provide a suitable system, both from thestandpoint of suitable attachment to an adjacent tray assembly and fromthe desirability of being adequately affixed to the supporting beams inthe germination compartment.

SUMMARY OF THE INVENTION

It is the objective of the invention to provide an improved trayassembly capable of providing enhanced cleaning after germination andbetter air flow during the germination cycle. The tray assembly of theinvention further provides a rigid germination floor, when a pluralityof tray assemblies are affixed together by a unique technique. Clampmeans may also be used in accordance with the teachings herein to securethe floor to underlying support beams.

The tray assemblies of the invention are uniquely designed to providecleaning access as there are no pockets or cavities where slime andcontamination build up as in the prior art, such as between adjacenttray assemblies and within the closed frame and support members. Theunprotected ends of adjacent tray sheets have been eliminated to providea flat floor which is not subject to damage from plow boards or helicalgrain turning machines.

The tray assembly herein disclosed is stronger and stiffer and allows0.060" thick stainless steel tray sheets, preferred by many maltsters,to be used. The floor area of the floor, despite its enhanced strength,has approximately 0.05% closed area in contrast to the approximate 24%of prior art tray assemblies. This permits greater flow during thegermination process.

The frame structure of the invention supporting the tray sheet haspassages and open areas through which cleaning wash can easily flow toeliminate the problems of slime and contaminants whereby cleaning can bequickly and effectively accomplished by a reduced work crew. Suitablecleaning can be achieved from above the floor, because of the uniqueconfiguration of the tray assembly permitting a free flow of washliquid. Thereby, the cleaning crew requires minimal time and effort toclean in the less desireable sub-floor compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top partial plan view with a portion of tray sheet shown ofa first embodiment of a plurality of tray assemblies of the invention;

FIG. 2 is a partial side elevational view with parts in section of theplurality of tray assemblies taken along line 2--2 of FIG. 1;

FIG. 3 is a top perspective view of the frame of a tray assembly of FIG.1;

FIG. 4 is a side plan view with parts in section of a portion of a trayassembly frame taken along line 4--4 of FIG. 1;

FIG. 5 is an end plan view with parts in section taken along line 5--5of FIG. 1;

FIG. 6 is a top partial plan view with a portion of a tray sheet shownof another embodiment of a plurality of tray assemblies of theinvention;

FIG. 7 is a partial side elevational view with parts in section of theplurality of tray assemblies taken along line 7--7 of FIG. 6;

FIG. 8 is a partial end elevational view of a first embodiment usingriser members with the tray assemblies of FIG. 6;

FIG. 9 is a top perspective view of the frame of a tray assembly of FIG.6;

FIG. 10 is a side elevational view with parts in section of a trayassembly riser taken along line 10--10 of FIG. 6;

FIG. 11 is a side elevational view with parts in section of a trayassembly riser at a bolt hole taken along line 11--11 of FIG. 6; and

FIG. 12 is a side elevational view with parts in section of a riserblock assembly at attachment locations between adjacent tray assembliestaken along line 12--12 of FIG. 6,

FIG. 13 is a perspective front view of the riser shown in FIG. 11;

FIG. 14 is a side elevational view of the riser of FIG. 13;

FIG. 15 is a plane view of the riser of FIG. 13;

FIG. 16 is a front elevational view of the riser of FIG. 10;

FIG. 17 is a perspective front view of the riser of FIG. 10;

FIG. 18 is a side elevational view of the riser of FIG. 17;

FIG. 19 is a top plan view of the riser of FIG. 17;

FIG. 20 is a front elevational view of the riser of FIG. 17;

FIG. 21 is a front perspective view of one of the risers used at theposition shown in FIG. 25;

FIG. 22 is a top plan view of the riser of FIG. 21;

FIG. 23 is a front elevational view of the riser of FIG. 21;

FIG. 24 is a side elevational view of the riser of FIG. 21.

FIG. 25 is a partial end elevational view of a second embodiment usingalternative riser members with the tray assemblies of FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIGS. 1-5, there is illustrated the improved trayassemblies of the invention, generally designated by reference numeral2, forming the floor of a germination compartment. The tray assemblies 2include an upper tray sheet 4 having a plurality of perforations 6 and asupporting frame structure 8. The tray sheets 4 support the grain duringmalting and the perforations 6 permit the circulation of humid airthrough the floor during germination. The upper tray sheets 4 areaffixed to a respective frame structure by spot welding and the like.

The frame structure 8 for each tray assembly consists of a pair ofparallel side members 10 interconnected to each other at each end by apair of cross frame members 12 as best seen in FIGS. 1 and 3. Aplurality of spaced longitudinal ribs 14, for example, the five shown inFIG. 3, extend parallel to the side members 10 and span between crossframe members 14. A plurality of reinforcing bars 16 extend in two rowsrespectively between the side members 10 and an adjacent rib 14 andbetween adjacent ribs 14. The foregoing components of the framestructure 8 are fabricated from a metal and may be interconnected as aunit by a suitable attachment technique, such as welding.

The side members 10, cross frame members 12, ribs 14, and bars 16 allhave a relatively narrow thickness in the plan view of FIG. 1 to insurenearly unimpeded flow of air or cleaning wash through the perforatedtray sheet 4. The plurality of floor assemblies are carried by aplurality of substructure I-beams 18 supported on the walls (not shown)of the germination compartment. As best seen in FIGS. 2 and 4 the endsof adjacent tray assemblies are bolted together by bolt asssemblies 20at the position of support of respective I-beams 18.

The end portions 22 of the tray sheet 4 of each tray assembly are bentdown against the cross frame member 12 whereby the end portions 22 ofadjacent tray sheet 4 are sandwiched between the cross members ofadjacent frame members as best seen in FIG. 4. As seen in FIG. 3 a crossmember 12 has a pair of holes 24 to receive a pair of bolt assemblies 20at each end to end connection of tray assemblies 2. The bolt assembliesextend between adjacent cross frame members 12 through aligned holes 26in the bent down end portion 22 of the tray sheets 4. The foregoingattachment technique eliminates the hidden pockets where slime andcontamination buildup in prior art tray assemblies where the edge oftray sheet of one tray assembly overlaps the adjacent tray assembly.Further, the bent down portion 22 of the tray sheets 4 eliminatesexposed free edges of tray sheets of prior germination floors and reducethe damage caused by grain turning machines or plows used in connectionwith the malting process. The bent down tray sheets 4 also provide aflatter floor with minumum deflection.

As best seen in FIG. 5, the adjacent tray assemblies 4 are attached inside by side relationship by bolt assemblies 30 positioned in thealigned holes 32 (FIG. 3) of adjacent side members 10. The previouslydescribed frame structure 8 and bolt interconnections of the trayassemblies provide enhanced rigidity and structural integrity to thegermination floor. The side by side attachment by bolts 34 alsoeliminates undesirable pockets where slime and contaminants can buildup.

As seen in FIG. 3, a pair of bolts holes are formed in each of the ribsinclude a pair of holes 36 for attaching the clamp assembly 38 of FIG.4. The clamp assembly 38 includes an approximate U-shaped body 40 havingan upper portion 42 being affixed to ribs 14 by bolt assembly 44extending through hole 36. The bottom portion 46 of the clamp assembly38 projects beneath a section of an I-beam 18. A threaded member 48extends through a hole 50 formed in the lower portion 46 and acooperating nut 52 to clamp the frame structure to the supportingI-beams. A clamp assembly 38 may be employed at each of I-beams 18 bybeing attached to as many of the ribs 14 as necessary for securement.

As illustrated in FIG. 3, the cross frame members 12 are formed withopen areas 54 so that the lower edge of the frame members 12 is spacedabove the upper surface of I-beams 18. This permits free flow of liquidwash through the open areas 54 between adjacent tray assemblies toprovide optimum cleaning. As further seen in FIG. 4, the bottom edges 56of ribs 14 are spaced above the I-beams 18 to create additional openareas 58. The open ares 58 allow additional flow of wash to flush thetray assemblies 2 and I-beams 18.

Referring to FIG. 6 to 12 there is illustrated another embodiment oftray assemblies of the invention, generally designated by referencenumeral 100. The tray assembly 100 includes a perforated tray sheet 102(FIG. 6) such as described in the preceding embodiment with reference toFIGS. 1 to 5. The tray sheet 102 is affixed to a tray frame 104 by spotwelding and the like. The frame includes a pair of side frame members106. A pair of cross frame members 108 are connected to the ends of theside frame members 106. A plurality of longitudinal reinforcing rods 110extend in parallel relationship to side members 106 between cross framemembers 108. Two rows of reinforcing bars 112 extend laterally acrossthe frame 104 in similar manner as the previous embodiment. The heightof the side frame members 106, cross members 108, and reinforcing rods110 are all equal in contrast to the embodiment of FIGS. 6-12. Free flowof wash liquid during cleaning is provided by unique risers inaccordance with the invention to be described. The tray assemblies 100are affixed together in a side by side relationship by bolt assemblies(not shown) through holes 106a (FIG. 9) in inside members 106 as inpreceding embodiments.

In a first embodiment, as best shown in FIGS. 8, 10, and 17 to 20, apair of slip-on risers 120 are shown to elevate the tray frame 102 fromI-beam 18 at two postions at each of the tray assemblies. The slip-onriser 120 is intended to be used at positions on I-beams 18 betweenadjacent tray assemblies 100 and may be attached to the I-beams 18 bybolts (not shown) through elongated hole 121 that allows some adjustmentof position. The slip-on risers 120 include a casting 122 having anenlarged base 124. The top of casting includes a modified U-shapedconfiguration having upward opening arms 126, 128 and base 129 toprovide cavity 130 to receive the side beams 108 and bent down endportions 102' of adjacent tray sheets 102.

The bolted position of the end to end relationship of tray assemblies100 are supported by additional risers 140 shown in FIGS. 8, 11, and 13to 16. As in the previous embodiment, the end of a tray assembly 100 isbolted to another tray assembly by bolt assemblies 142 through holes 144in cross members 108 (FIG. 9). The ends 102' of the tray sheets 102 aresandwiched between the cross frame members 108 as previously described.

In addition, the riser 140 includes a base 146 and an upper verticalplate 148 as shown in FIGS. 11, and 13 to 16. The base 146 forms asaddle surface 148' for the cross members 108. The plate 148 includes ahole 150 to receive a bolt assembly 142 which also extends through theframe members 108 and bent down portion 102'. Another elongated slot 151is formed through base 146 for attachment to the I-beam 18 by a bolt(not shown) and allows limited adjustment of the position of the riser140. The riser 140 is positioned adjacent to two bolt interconnectionsbetween the adjacent ends of the tray assemblies.

In another embodiment as shown in FIGS. 12, and 21 to 25, an alternatepair of risers 160 are connected to the side frame members 106 incontacting side beams 106. Each riser 160 is formed as a casting 162having a cut-out saddle surface 164 and hole 165. A bolt assembly 166extending through hole 165 located beneath the frame 102 affixes thepair of risers 160 together clamping them to the adjacent frame 102.(FIG. 25). The saddle surface 164 is disposed beneath the side framemembers 106 of adjacent frames 102 to elevate the side frame members106. The pair of risers 160 at each position bear against each otherbeneath beams 106 at surfaces 170. The saddle portion 164 is defined bya pair of upper offset portions 174. As seen in FIG. 25, the risers 160are used in conjuction with previously described risers 120.

In both alternative arrangements in FIG. 8 and FIG. 25, the risers areparticularly useful in situations where the height of the frame 104 isshallow, compared to the greater height of the frame structure 8 of theembodiment of FIGS. 1 to 5. It is commonly preferred that the verticalposition of the germination floor be at a height dictated by deepframes, such as, for example, approximately four inches above the I-beam18 as provided by the frame structure 8 of FIG. 3. The height of frame104 with the risers herein disclosed elevate the tray sheets 102 toapproximately the height dictated by a deep tray assembly. This elevatedposition of tray frame 104 also provides enhanced circulation of liquidwash during cleaning between adjacent trays through I-beams 18 forincreased cleaning of both.

What is claimed is:
 1. The tray assemblies for the floor of agermination compartment comprising:a plurality of frame means having atop surface and a lower surface, said frame means including a pair ofspaced side members interconnected with a pair of cross members, saidframe means further including a plurality of spaced rib membersextending parallel to said side members, said rib members being attachedat each end to said cross members, a perforated tray sheet being affixedto the top of each of said plurality of said frame means, said lowersurface being arranged to be carried by cross supporting beams locatedbeneath said cross member, riser means positioned between said framemeans and the supporting beams to raise said plurality of frame meansabove the supporting beams, said riser means having a base disposed incontacting relationship beneath one of said cross members of said framemeans and one of said cross members of a said adjacent frame means, andsaid riser means further having means contacting said frame means andsaid adjacent frame means at a position above said base.
 2. The trayassemblies for the floor of a germination compartment comprising:aplurality of frame means having a top surface and a lower surface, saidframe means including a pair of spaced side members interconnected witha pair of cross members, said frame means further including a pluralityof spaced rib members extending parallel to said side members, said ribmembers being attached at each end to said cross members, a perforatedtray sheet being affixed to the top of each of said plurality of saidframe means, said lower surface being arranged to be carried by crosssupporting beams located beneath said cross members, and riser meanspositioned between said frame means and the supporting beams to raisesaid plurality of frame means above the supporting beams, said risermeans includes a plurality of first riser members each having a basedisposed on the supporting beams, each of said riser members furtherhaving an upper portion disposed adjacent to the cross member of one ofsaid frame means, bolt means extending respectively through said upperportion of said cross member of one of said frame means and the crossmember of an adjacent one of said frame means to affix said one and saidadjacent one of said frame means in end to end relationship.
 3. The trayassemblies according to claim 2 wherein said perforated tray sheet ofeach of said plurality of frame means includes an edge portion bent downbetween said one and said adjacent one of said frame means.
 4. The trayassemblies according to claim 3 further including a plurality of secondriser members positioned between each of said cross members and arespective supporting beam in spaced relationship to said first risermembers, said second riser member having a base carried by a respectivesupport beam, said second riser further including an upward openingU-shaped portion to receive the bottom of one of said cross frames ofsaid one and said adjacent one of said frame means.
 5. The trayassemblies for the floor of a germination compartment comprising:aplurality of frame means having a top surface and a lower surface, saidframe means including a pair of spaced side members interconnected witha pair of cross members, said frame means further including a pluralityof spaced rib members extending parallel to said side members, said ribmembers being attached at each end to said cross members, a perforatedtray sheet being affixed to the top of each of said plurality of saidframe means, said lower surface being arranged to be carried by crosssupporting beams located beneath said cross members, and riser meanspositioned between said frame means and the supporting beams to raisesaid plurality of frame means above the supporting beams, said risermeans includes a plurality of pairs of riser members, said pairs ofriser members having bottom portions carried by a respective supportingbeam, said pairs of riser members being disposed on opposite sides ofthe side members of adjacent frame means, bolt means for affixing saidpairs of riser members to said side members of adjacent frame means, andsaid riser members forming a surface beneath the cross members ofadjacent frame means.